For designers and engineers worldwide, bringing a concept to life with both visual realism and functional integrity has often required a difficult choice: create a beautiful prototype or a durable one. PolyJet 3D printing ends this compromise. As a leading online custom parts fabricator, Lava3DP is leveraging this advanced technology to deliver parts that offer an unparalleled combination of high resolution, multi-material properties, and vibrant color, all within a single build. This article explores how PolyJet technology can accelerate your product development and transform your custom part fabrication.

What is PolyJet 3D Printing?

PolyJet is a powerful photopolymer 3D printing technology that operates in a manner similar to traditional inkjet printing. However, instead of jetting ink onto paper, PolyJet printers jet liquid photopolymer resin onto a build tray in ultra-thin layers, which are instantly cured by ultraviolet (UV) light . This layer-by-layer process allows for the creation of complex shapes, smooth surfaces, and intricate details with exceptional accuracy.

The technology is renowned for its high precision and ability to produce parts with smooth surfaces straight from the printer, often requiring minimal post-processing . Furthermore, it is an office-friendly solution due to its clean operation and minimal waste .

Key Advantages of PolyJet for Custom Parts

PolyJet technology stands out in the additive manufacturing landscape for several compelling reasons that are particularly beneficial for custom part fabrication.

1. Unmatched Precision and Surface Quality

PolyJet printers build parts with incredibly fine layer resolutions. For instance, the Stratasys Eden 260VS can achieve a layer thickness as fine as 16 microns . This results in models with smooth surfaces, fine details, and minimal visible layer lines, making it ideal for prototypes that need to look and feel like a production-ready product.

2. Multi-Material and Full-Color Capability

This is perhaps the most significant advantage of PolyJet technology. Advanced systems like the Stratasys J850 can simultaneously load up to seven different materials, allowing for the creation of a single part with varying properties, such as a rigid frame with soft-touch grips . This multi-material capability is powered by “Digital Materials,” which enable the printer to mix two or more base resins to create composite materials with hundreds of predefined combinations of mechanical properties .

Moreover, this technology supports full-color 3D printing. The J850 printer, for example, can produce parts with over 500,000 colors , allowing for hyper-realistic prototypes that can be used for market research, sales samples, and design validation.

3. Material Versatility

PolyJet offers a wide range of material properties, capable of simulating everything from rigid plastics to rubber-like elastomers.

Below is a summary of available material types and their key applications:

4. Speed for Rapid Iterations

In the competitive landscape of product development, speed is critical. PolyJet printing is fast, enabling the production of complex, multi-material parts in hours, not days. This allows design teams to conduct more design iterations in less time, significantly shortening the product development cycle and helping them get to market faster .

The Game-Changer: Introducing ToughONE Material

A common historical limitation of PolyJet resins was their brittleness, which made them less suitable for functional testing under stress. This has been decisively addressed with the 2025 introduction of ToughONE, a new class of material from Stratasys .

ToughONE is engineered for functional prototyping and selected end-use parts. It provides enhanced impact resistance, flexibility, and toughness without sacrificing the signature PolyJet benefits of surface smoothness, high resolution, and dimensional stability . This material is ideal for creating parts that must withstand real-world use, such as snap-fit assemblies, living hinges, custom electronic enclosures, and durable jigs and fixtures .

Comparison of Traditional PolyJet Material Limitations vs. ToughONE’s Advancements:

Industries and Applications

The unique capabilities of PolyJet make it suitable for a vast array of industries. At Lava3DP, we have utilized it to solve complex challenges across multiple sectors.

• Consumer Electronics: Create full-color, multi-material prototypes of device housings, buttons, and seals that look and feel like the final product. ToughONE is perfect for impact-resistant elements and custom charger casings .
• Automotive: Produce realistic tail light covers, durable dashboard components, and ergonomic tools for assembly lines. Companies like Audi have used the J750 to create tail light prototypes, saving up to 50% in time compared to traditional methods .
• Medical Devices: Develop highly accurate, biocompatible models for surgical planning, training, and device prototyping. The technology allows for the creation of multi-colored anatomical models that differentiate between tissues, bones, and blood vessels .
• Consumer Goods: From packaging with living hinges to product designs that combine rigid and soft-touch elements, PolyJet enables comprehensive design validation before mass production. Companies like Suntory have used PolyJet to 3D print molds for bottle design, dramatically accelerating development time .

Partner with Lava3DP for Your Next Project

At Lava3DP, we are dedicated to providing our global clientele with cutting-edge manufacturing solutions. Our expertise in PolyJet 3D printing allows us to deliver custom parts that bridge the gap between aesthetic appeal and functional performance. Whether you need a hyper-realistic model for client presentation, a multi-material assembly for design verification, or a robust functional prototype made with ToughONE, we have the technology and expertise to bring your vision to life.

Ready to transform your custom part fabrication? Contact us today to discuss your project and receive a quote.

FAQ

❓ Q: What is the cost and lead time of PolyJet printing service?

💬 A: It depends on the volume and weight of the design. The lead time is about 2-3 days.

❓ Q: What is the biggest parts can you 3d print with PolyJet printing service?

💬 A: The biggest dimensions we can 3d print is 1000*800*500mm.

❓ Q: Can you ship to Europe?

💬 A: Yes. We can deliver our goods around the world. We have partners that can ship the parcel to you with DHL, FedEx, UPS, Freight, Sea and other shipping solutions.

❓ Q: Is the surface of the full color part is very smooth?

💬 A: Yes. The surface can be 3d printed according to the design. The detais are super vivid.